Use of Geo-composites to Optimise Track Renewals and Maintenance

Presentation Overview Tracktex™ - Anti-Pumping Geocomposite Before we start, I would like to provide with you a very quick overview on Geofabrics, our Company.

Company Overview Geofabrics Australasia is:  the Australian geosynthetic specialist  a National Company with a 36 year history  2 manufacturing plants  a NATA accredited laboratory  a research laboratory  12 offices Australia wide  more than 120 employees  technical services division

Brisbane Office Ormeau Factory, Centre of Excellence Testing Facility – Gold Coast Geotextile Factory - Albury Melbourne Head Office

Manufacturing Plant Albury, NSW

Geosynthetic Centre of Excellence GCL Hydraulic Conductivity Transmissivity GCL Internal Shear and Interface Friction Geogrid Shear Resistance 50kN Universal Testing Machine Liner Protection Real Time UV Resistance GCL Flow Box Abrasion Resistance

In 2013 a lamination line was commissioned at our Albury plant to attach bidim geotextile to Tensar geogrid & drainage geonets. This reduces the installation time taken on site, & in some instances will reduce the lead-time for supply. We have recently completed a second glue application method to provide greater flexibility for future product development eg. Tracktex™.

Tracktex ™ The Anti-Pumping Geocomposite

9 Phil Sharpe – Tracktex launch in May2014 Trackbed Performance – Maintainance Cycle Trackbed Failure – Historical use of Geosynthetics Subgrade/Formation erosion - Separation Soft formation - Reinforcement Trackbed Investigation Development of Anti-Pumping Geocomposites Case History – Tracktex solves problems at Bradley Junction Overview

10 Phil Sharpe – Tracktex launch in May2014 Trackbed Performance – Maintainance Cycle Trackbed Failure – Historical use of Geosynthetics Subgrade/Formation erosion - Separation Soft formation - Reinforcement Trackbed Investigation Development of Anti-Pumping Geocomposites Case History – Tracktex solves problems at Bradley Junction Overview

Problem – Track Geometry

Ballast Degradation No problem with Capping layer

Subgrade Erosion/ Mud Pumping

Development of Anti-Pumping Geocomposites Development took 10 years from

Investigated Geotextiles Geomembranes Sand Blankets

Investigated Geotextiles Geomembranes Sand Blankets

Investigated Geotextiles Geomembranes Sand Blankets

Investigated Geotextiles Geomembranes Sand Blankets

Geosand The first Anti-Pumping Geocomposite

Full Scale Test Rig Geofabrics UK developed Test Rig 4.5m x 1.5m

Details of Full Scale Testing of Trial Geosynthetics Clay Pre-existing mud pumping Half sleeper 300mm ballast Actuators Trial geosynthetic Half 600mm centres Irrigation Plan View Actuators 20 Tonne Axle load and simulate a rolling load

Mud Pumping Reproduced in Rig Most aggressive environment – mixture of clay and ballast

Geotextile Mud pumping through Geotextile Pore Size of Geotextile – microns Clay Particles – 1-2 microns

Anti Pumping Geocomposite

Anti Pumping Geocomposite after 70 MGT – no mud pumping, ballast dust only

Underlying Mud Retained after 70 MGT

That was UK Product! Tracktex ™ Australia

The Journey  Began in early 2012  Tracktex ™ made in UK by Geofabrics UK  Geotextile – Nonwoven, Staple Fibre, Needle Punched  Geofabrics Australasia make Nonwoven, Continuous Filament, Needle Punched in Australia  Introduced lamination line in 2013  Our aim – make Tracktex ™ in Australia

Geofabrics UK specification for Tracktex ™

Geofabrics Australasia Initial Research  Made a number of Prototypes  Utilised PVC Core  A number of Geotextile combinations  Tested for Mechanical Strengths  Made use of facilities at Centre of Excellence  Liner protection testing apparatus

Geofabrics UK specification

Geofabrics UK Rail Rig

Australian Manufacture  Albury plant  Upgraded lamination equipment

Trial Holes excavated 2 years after installation in area previously slurried

Half Sleeper Rig Test Apparatus Rigid base Rubber Geogrid 150mm ½ scale ballast 100mm sand ½ scale model half-sleeper (100 x 600 x 80mm deep) Cyclic loading

Effect of base stiffness on ballast settlement Effect of reinforcement – firm base Effect of reinforcement - soft base Half-sleeper rig – Test Results Firm Base Rigid Base Unreinforced Reinforced – Tensar SS1 Unreinforced Reinforced Tensar SS1 Reinforced – Steel Mesh Reinforced Tensar 3005/2

Shirland Trials - Examination after 18 Years in Trackbed no significant deterioration of the properties of strength and strain microscopic examination shows that the rib surface retains much of its original uniform and plain texture. the product appears to offer considerably more than 20 years operational service life